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Hydrodynamic Analysis of Binary Immiscible Metallurgical Flow in a Novel Mixing Process: Rheomixing
This paper presents a hydrodynamic analysis of binary immiscible metallurgical flow by a numerical simulation of the rheomixing process. The concept of multi-controll is proposed for classifying complex processes and identifying individual processes in an immiscible alloy system in order to perform simulations. A brief review of fabrication methods for immiscible alloys is given, and fluid flow aspects of a novel fabrication method – rheomixing by twin-screw extruder (TSE) are analysed. Fundamental hydrodynamic micro-mechanisms in a TSE are simulated by a piecewise linear (PLIC) volume-of-fluid (VOF) method coupled with the continuum surface force (CFS) algorithm. This revealed that continuous reorientation in the TSE process could produce fine droplets and the best mixing efficiency. It is verified that TSE is a better mixing device than single screw extruder (SSE) and can achieve finer droplets. Numerical results show good qualitative agreement with experimental results. It is concluded that rheomixing by a TSE can be successfully employed for casting immiscible engineering alloys due to its unique characteristics of reorientation and surface renewal
Modelling the Interfacial Flow of Two Immiscible Liquids in Mixing Processes
This paper presents an interface tracking method for modelling the flow of immiscible metallic liquids in mixing processes. The methodology can provide an insight into mixing processes for studying the fundamental morphology development mechanisms for immiscible interfaces. The volume-of-fluid (VOF) method is adopted in the present study, following a review of various modelling approaches for immiscible fluid systems. The VOF method employed here utilises the piecewise linear for interface construction scheme as well as the continuum surface force algorithm for surface force modelling. A model coupling numerical and experimental data is established. The main flow features in the mixing process are investigated. It is observed that the mixing of immiscible metallic liquids is strongly influenced by the viscosity of the system, shear forces and turbulence. The numerical results show good qualitative agreement with experimental results, and are useful for optimisating the design of mixing casting processes
Kaedah pembelajaran lukisan kejuruteraan berasaskan simulasi
Kajian yang dijalankan ini adalah untuk melihat kebolehgunaan sebuah perisian pendidikan yang menerapkan Kaedah Pembelajaran Lukisan Kejuruteraan Berasaskan Simulasi bagi menyelesaikan masalah kurang faham , kurang minat dan kebergantungan yang terlalu memusat kepada guru di kalangan pelajar Tingkatan 4, Sekolah Menengah Ungku Aziz, Sabak Bernam, Selangor . Justeru, penyampaian isi kandungan yang bersesuaian dengan tahap pemikiran atau kognitif pelajar, aspek minat dan motivasi serta pembelajaran ala akses kendiri dirasakan sebagai faktor utama yang ingin dikenal pasti dalam perisian yang dibangunkan bagi menyelesaikan masalah tersebut. Macromedia Authorware versi 6.5 dipilih sebagai bahasa pengarangan bagi membangunkan perisian pendidikan ini. Seramai 30 responden dipilih untuk mendapatkan maklum balas terhadap kajian ini. Data yang didapati telah dianalisis menggunakan perisian Statistical Package for Social Science (SPSS) versi 11.0 menggunakan kaedah deskriptif min. Hasil kajian mendapati bahawa maklum balas adalah positif terhadap faktor-faktor yang telah dikaji
Relationship between solidification microstructure and hot cracking susceptibility for continuous casting of low-carbon and high-strength low-alloyed steels: A phase-field study
© The Minerals, Metals & Materials Society and ASM International 2013Hot cracking is one of the major defects in continuous casting of steels, frequently limiting the productivity. To understand the factors leading to this defect, microstructure formation is simulated for a low-carbon and two high-strength low-alloyed steels. 2D simulation of the initial stage of solidification is performed in a moving slice of the slab using proprietary multiphase-field software and taking into account all elements which are expected to have a relevant effect on the mechanical properties and structure formation during solidification. To account for the correct thermodynamic and kinetic properties of the multicomponent alloy grades, the simulation software is online coupled to commercial thermodynamic and mobility databases. A moving-frame boundary condition allows traveling through the entire solidification history starting from the slab surface, and tracking the morphology changes during growth of the shell. From the simulation results, significant microstructure differences between the steel grades are quantitatively evaluated and correlated with their hot cracking behavior according to the Rappaz-Drezet-Gremaud (RDG) hot cracking criterion. The possible role of the microalloying elements in hot cracking, in particular of traces of Ti, is analyzed. With the assumption that TiN precipitates trigger coalescence of the primary dendrites, quantitative evaluation of the critical strain rates leads to a full agreement with the observed hot cracking behavior. © 2013 The Minerals, Metals & Materials Society and ASM International
Research and development of the solidification of slab ingots from special tool steels
The paper describes the research and development of casting and solidification of slab ingots from special tool steels by means of numerical modelling using the finite element method. The pre-processing, processing and post-processing phases of numerical modelling are outlined. Also, problems with determining the thermophysical properties of materials and heat transfer between the individual parts of the casting system are discussed. Based on the type of grade of tool steel, the risk of final porosity is predicted. The results allowed to improve the production technology of slab ingots, and also to verify the ratio, the chamfer and the external/internal shape of the wall of the new designed slab ingots.Web of Science6231458145
The cooperation of Russian and German metal forming scientific schools to develop the new energy-efficient materials and technologies
The future scientific orientation of Katedra PDSS is in the area of materials forming and materials development with a focus on efficient processes regarding the use of energy and resources. Current research in the department PDSS is based on fundamental works on thermo-mechanical treatment of metals and on the modeling of nano-materials, rolled material and medical materials. This includes research on the relevant microstructural and macroscopic effects on the materials behavior. Together with its international research partners PDSS has excellent foundations for experimental research as well. With its international focus and its educational programs for students and skilled employees PDSS is an important partner of the Russian metal processing industry which supports Russian companies to compete on a world-class level
Opazovanje in simulacija nestabilnih pogojev med kontinuirnim litjem
Continuous casting comprises thermal, mechanical and chemical processes running in a complex system that contains a number of elements, such as a solidifying steel strand, a mould with an oscillation mechanism, a withdrawal mechanism, a water cooling sub-system with nozzles, several control sub-systems, etc. An external observer might see the process as robust and stable, but in reality there are fluctuations in the internal thermal and mechanical quantities, reflected in the structure and quality of the product. The research on unsteady behaviour of the quantities such as a solidifying strand temperature field, solid shell thickness and metallurgical length was conducted using an industrial diagnostic system DGS complemented with special measurement equipment and a thermal numerical model. Selected results of the monitoring and simulation of the non-standard process states are shown and analysed in the paper. Methods for determining the boundary conditions for the numerical model are also presented. The effect of the Leidenfrost phenomenon on the heat-transfer coefficient during water cooling by nozzles is also discussed. Since the determination of precise and immediate boundary conditions has technical limits, the model provides only smoothed values in time and space. As knowledge of the instantaneous state of the fluctuating process is a prerequisite for achieving quality and defect-free production, it is appropriate to complement the thermal numerical model by on-line monitoring of the machine's internal state. The results of the simulations are closely linked to the real process data.Kontinuirno litje obsega termične, mehanske in kemične procese, ki tečejo v kompleksnem sistemu, ki vsebuje vrsto elementov,
kot so: strjujoča se jeklena žila (gredica), kokila z oscilacijskim mehanizmom, izvlečni mehanizem, vodno hlajenje s podsistemom
hladilnih šob, več kontrolnih podsistemov itd. Zunanji opazovalec lahko vidi proces kot robusten in stabilen, toda v
resnici imamo vrsto fluktuacij (nihanj) internih termičnih in mehanskih veličin in kakovosti produkta (nastajajoče konti lite
gredice). Raziskave (časovno) nestabilnega obnašanja veličin, kot so: temperaturno polje strjujoče se konti gredice, debelina
trdne skorje in metalurška dolžina, so avtorji prispevka izvajali z industrijskim diagnostičnim sistemom (DGS), dopolnjenim s
specialno merilno opremo in termičnim numeričnim modelom. V članku avtorji predstavljajo izbrane rezultate analiz,
opazovanja in simulacije nestandardni procesnih stanj. Prav tako predstavljajo metode določevanja robnih pogojev za numerični
model. Diskusija obsega tudi t.i. Leidenfrostov fenomen in njegov vpliv na koeficient prenosa toplote med vodnim hlajenjem s
šobami. Za natančno določitev vsakokratnih robnih pogojev obstajajo tehnične omejitve. Zato so v postavljenem modelu
uporabljene le zglajene vrednosti v realnem času in prostoru. Poznavanje trenutnega stanja ves čas spreminjajočega stanja, je
predpogoj za doseganje kvalitetne proizvodnje brez napak. Zato je primerno uporabljati termični numerični model s tekočim
(on-line) oz. neposrednim spremljanjem internega stanja na konti livni napravi. Predstavljeni rezultati so tesno povezani z
realnimi procesnimi podatki.Web of Science52211711
The improvement of aluminium casting process control by application of the new CRIMSON process
All The traditional foundry usually not only uses batch melting where the
aluminium alloys are melted and held in a furnace for long time, but also uses
the gravity filling method in both Sand Casting Process (SCP) and Investment
Casting Process (ICP). In the gravity filling operation, the turbulent behaviour
of the liquid metal causes substantial entrainment of the surface oxide films
which are subsequently trapped into the liquid and generate micro cracks and
casting defects. In this paper a new CRIMSON process is introduced which
features instead of gravity filling method, using the single shot up-casting
method to realize the rapid melting and rapid filling mould operations which
reduce the contact time between the melt and environment thus reducing the
possibility of defect generation. Another advantage of the new process is the
drastic reduction of energy consumption due to shortened melting and filling
time. Two types of casting samples from SCP and ICP were compared with the new
process. The commercial software was used to simulate the filling and
solidification processes of the casting samples. The results show that the new
process has a more improved behaviour during filling a mould and solidification
than the two conventional casting processes
A design-for-casting integrated approach based on rapid simulation and modulus criterion
This paper presents a new approach to the design of cast components and their associated tools. The current methodology is analysed through a case study and its main disadvantages underlined. Then, in order to overcome these identified drawbacks, a new approach is proposed. Knowing that this approach is mainly based on a rapid simulation of the process, basics of a simplified physical model of solidification are presented as well as an associated modulus criterion. Finally, technical matters for a software prototype regarding the implementation of this Rapid Simulation Approach (RSA) in a CAD environment are detailed
Thermophysical Phenomena in Metal Additive Manufacturing by Selective Laser Melting: Fundamentals, Modeling, Simulation and Experimentation
Among the many additive manufacturing (AM) processes for metallic materials,
selective laser melting (SLM) is arguably the most versatile in terms of its
potential to realize complex geometries along with tailored microstructure.
However, the complexity of the SLM process, and the need for predictive
relation of powder and process parameters to the part properties, demands
further development of computational and experimental methods. This review
addresses the fundamental physical phenomena of SLM, with a special emphasis on
the associated thermal behavior. Simulation and experimental methods are
discussed according to three primary categories. First, macroscopic approaches
aim to answer questions at the component level and consider for example the
determination of residual stresses or dimensional distortion effects prevalent
in SLM. Second, mesoscopic approaches focus on the detection of defects such as
excessive surface roughness, residual porosity or inclusions that occur at the
mesoscopic length scale of individual powder particles. Third, microscopic
approaches investigate the metallurgical microstructure evolution resulting
from the high temperature gradients and extreme heating and cooling rates
induced by the SLM process. Consideration of physical phenomena on all of these
three length scales is mandatory to establish the understanding needed to
realize high part quality in many applications, and to fully exploit the
potential of SLM and related metal AM processes
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